Method of sheet accumulation using sideways saddle motion

ABSTRACT

A sheet collecting apparatus includes a fold blade having a fold axis in a first direction, a collecting device for supporting folded sheets of material in a stack arranged for stapling, and a translation device. The collecting device is mounted to the translation device for translation in a first direction from a first position to a second position. In the first position, a sheet-collecting portion of the sheet-supporting edge subtends the fold blade and in the second position the sheet-collecting portion of the sheet-supporting edge is clear of the fold blade. Optionally, the fold blade is cantilevered to position the fold blade above a sheet-collecting portion of the sheet-supporting edge. An exemplary method to accumulate sheets on a collecting device on a sheet-wise basis includes translating the collecting device in a translating direction from the first position to the second position to remove the folded sheet from the fold blade and to transfer the folded sheet to the collecting device.

BACKGROUND

Duplex printed sheets are often bound into finished documents, such as booklets, by a paper-handling accessory. Machines perform finishing operations, such as binding, folding, trimming, saddle stapling, and hole drilling. The handling of sheets of paper for booklet making includes additional manipulating operations such as collecting and positioning sheets of paper.

Inverted V-shaped workpieces have been utilized for collecting folded duplex printed sheets in booklet making systems. Generally, the workpiece is fixed or stationary and mechanical solutions are implemented to place the two portions of the folded sheet on opposite sides of the workpiece. In other systems, the workpiece is rotated to place the two portions of the folded sheet on opposite sides of the workpiece. In another system, the workpiece is moved perpendicular to a device upstream in the paper path, e.g., a folding apparatus, from a first position, in which the leading side of the sheet is positioned on a first side of the workpiece, to a second position, during which the trailing edge is dragged over and/or cleared from the upstream device and comes to rest on a second side of the workpiece. The above steps can be repeated until a required number of sheets have been collected.

SUMMARY

An exemplary sheet collecting apparatus comprises a fold blade having a fold axis in a first direction, a collecting device for supporting folded sheets of material in a stack arranged for stapling, the collecting device having a first side, a second side and a peak on a sheet-supporting edge, the peak having a peak axis in the first direction, and a translation device, the collecting device mounted to the translation device for translation in the first direction from a first position to a second position, wherein, in the first position, a sheet-collecting portion of the sheet-supporting edge subtends the fold blade, and wherein, in the second position, the sheet-collecting portion of the sheet-supporting edge is clear of the fold blade.

An exemplary sheet collecting apparatus in a sheet-wise booklet making system comprises a fold blade having a fold axis in a first direction; and a collecting device for supporting folded sheets of material in a stack arranged for stapling, the collecting device having a first side, a second side and a peak on a sheet-supporting edge, the peak having a peak axis in the first direction, wherein the fold blade is cantilevered above a sheet-collecting portion of the sheet-supporting edge.

An exemplary method to accumulate sheets on a collecting device on a sheet-wise basis comprises positioning a sheet-collecting portion of a collecting device below a fold blade, the sheet-collecting portion having a peak with a longitudinal peak axis parallel to a fold axis of the fold blade, the peak axis and the fold axis each oriented in a first direction, transferring a sheet to the fold blade, folding the sheet on the fold blade to position a first portion of the sheet on a first side of the collecting device, and translating the collecting device in a translating direction parallel to the first direction such that the translating removes the folded sheet from the fold blade and transfers the folded sheet to the collecting device.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The following detailed description of preferred embodiments can be read in connection with the accompanying drawings in which like numerals designate like elements and in which:

FIGS. 1A to 1C illustrates an exemplary sheet collecting apparatus.

FIG. 2 illustrates another view of the exemplary sheet collecting apparatus of FIGS. 1A to 1C.

FIG. 3 illustrates an exemplary method to accumulate sheets on a collecting device on a sheet-wise basis.

DETAILED DESCRIPTION

An exemplary sheet collecting apparatus is illustrated in FIGS. 1A-1C and FIG. 2. The exemplary sheet collecting apparatus 100 comprises a fold blade 102 having a fold axis in a first direction, a collecting device 104 for supporting folded sheets of material 106 in a stack arranged for stapling, and a translation device 108.

The collecting device 104 has a first side 110, a second side 112, and a peak on a sheet-supporting edge 114. The peak has a peak axis in the first direction. The peak axis is parallel with the longitudinal axis of the peak along the sheet-supporting edge 114. As shown in FIGS. 1A-1C and FIG. 2, the first direction is parallel to the illustrated x-axis.

The collecting device 104 is mounted to the translation device 108 for translation in the first direction from a first position (I) to a second position (II). In exemplary embodiments, the collecting device 104 translates in the sideways or lateral direction when viewed from a position normal to the first side 110 of the collecting device 104, e.g., when viewed in a direction parallel to the x-axis shown in the FIGS. 1A-1C and FIG. 2.

In the first position (I), a sheet-collecting portion 116 of the sheet-supporting edge 114 subtends the fold blade 102, as seen along a second direction. The second direction is substantially perpendicular to the first direction. As shown in FIGS. 1A-1C and FIG. 2, the second direction is substantially parallel with the y-axis. When the sheet-collecting portion 116 subtends the fold blade 102, the sheet-supporting edge 114 can be directly underneath the fold blade 102 or offset in the fold direction or the second direction as long as a first portion 118 of the folded sheet 106, e.g., a leading edge, is positioned on the first side 110 of the collecting device 104 and, optionally, a second portion 120 of the folded sheet 106, e.g., a trailing edge, is positioned on the second side 112 of the collecting device 104.

In the second position (II), the sheet-collecting portion 116 of the sheet-supporting edge 114 is clear from the subtended position with respect to the fold blade 102 as seen along the second direction. In an exemplary embodiment, the entire collecting device 104 is clear from the subtended position when the collecting device 104 is in the second position (II).

As used herein with respect to the position relationship between features of the sheet collecting apparatus, substantially perpendicular and substantially parallel means in a relative position in the designated orientation so that the operational characteristics as illustrated in the figures and described in the exemplary embodiments can be preserved, e.g., the paper is positioned over the fold blade with edges on different sides of the collecting device and the folded paper is transferred to the collecting device when the collecting device translates to the side from the subtended position.

Subtend is used herein to mean underlies or extends underneath. For example and with reference to the coordinate axis of FIG. 1, subtends means underlies or extends when viewed from a position along the positive y-axis, e.g., above the fold blade and fold housing.

The fold blade 102 can be any suitable fold blade to cooperate with a housing 122 to place a fold in sheet material, e.g., the housing 122 is translatable in a second direction to place a fold in sheet material positioned over the fold blade 102. Non-limiting examples of suitable fold blades and fold housings can be found in U.S. patent application Ser. Nos. 09/970,748; 09/970,840; 09/971,351 and 10/259,458. The fold blade 102 is cantilevered at a first end 124 of the fold axis to a mounting surface 126. The attachment of the fold blade 102 to the mounting surface 126 can be by any suitable means including, for example, adhesives, welding, bonding, by use of fasteners, e.g., nails, screws, and so forth, or any other suitable attachment means that maintains the cantilevered position of the fold blade under the forces exerted during a folding operation, e.g., by the cooperation of the housing 122 and the fold blade 102 to place folds in the sheets of material 106.

The translation device 108 can be any suitable translation device operable to translate the collecting device 104 from the first position I to the second position II. The translation device 108 shown in the exemplary embodiment includes a rail system with a drive belt, but any suitable translation device can be utilized including, but not limited to, rack and pinion systems, magnetic, electromagnetic, hydraulic, or other suitable forms of imparting motive force to, and/or coupling to, the collecting device to move the collecting device from a first position (I) to a second position (II). For example, and as shown in FIGS. 1A-1C, the translation device 108 can include at least one rail 128 with a longitudinal axis in the first direction and a drive motor 130 operably attached to the collecting device 104 to translate the collecting device 104 from the first position (I) to the second position (II). A first end of the translation device 108 is mounted to the mounting surface. In the embodiment shown, the at least one rail 128 of the translation device 108 is mounted at a first end 132 to the mounting surface 126.

The sheet collecting apparatus can also include a first sheet drive assembly 134 and optionally a second sheet drive assembly 136. The first sheet drive assembly 134 includes a first sheet contacting component 138. The first sheet contacting component 138 can be either static, e.g., free rolling, or powered. The first sheet drive assembly 134 is located on the first side 110 of the collecting device 104 and is operable to move between a sheet receiving position (i) and a sheet contacting position (ii). In the sheet receiving position (i) there is a gap 140 between the first side 110 of the collecting device 104 and the first sheet drive assembly 134. The first sheet drive assembly 134 can be operably mounted to allow portions of the folded sheets of material 106, e.g., the first portion 118, to be positioned between the first sheet drive assembly 134 and the collecting device 104.

The first sheet drive assembly 134 can be translatable in common with the collecting device 104. For example, the first sheet drive assembly 134 can be separably mounted from the collecting device 104 to be translated in unison therewith from the first position (I) to the second position (II). In other embodiments, the first sheet drive assembly 134 can be mounted in common with the collecting device 104. For example, as shown in FIGS. 1-2, the first sheet contacting component 138 of the first sheet drive assembly 134 is axially mounted to an edge of the collecting device 104. When the collecting device 104 is translated from the first position (I) to the second position (II) by the translation device 108, the first sheet drive assembly 134 also translates with the collecting device 104.

Similar to the first sheet drive assembly 134, the second sheet drive assembly 136 includes a second sheet contacting component 142. The second sheet drive assembly 136 is located on the second side 112 of the collecting device 104 and is operable to move between a sheet receiving position (i) and a sheet contacting position (ii). In the sheet receiving position (i), there is a gap 144 between the second side 112 of the collecting device 104 and the second sheet drive assembly 136. The second sheet drive assembly 136 can be mounted in any manner operable to translate with the collecting device 104. For example, the second sheet drive assembly 136 can be mounted in a manner consistent with the first sheet drive assembly 134. Alternatively, the second sheet drive assembly 136 can be mounted in a manner different from the first sheet drive assembly 134, but nevertheless consistent to maintain the relative position of the second sheet drive assembly 136 with respect to the second side 112 of the collecting device 104 during translation of the collecting device from the first position (I) to the second position (II). Furthermore, the operation of the second sheet drive assembly 136 can be consistent with the description of the operation of the first sheet drive assembly 134.

Exemplary embodiments of the sheet collecting apparatus 100 optionally include an ejection device 146 for elevating and/or removing the stack of folded sheet material 106 from the collecting device 104. As illustrated in FIG. 1C, an exemplary ejection device 146 can include ejection fingers. An exemplary ejection finger can optionally be recessed into the collecting device, and can extend and retract to move at least a portion, e.g., the folded peak portion, of a single sheet or a stack of sheets from a contacting position with the collecting device. The ejection fingers thereby expose a space between the folded sheet or stack of folded sheets into which anther support device can be inserted for subsequent transfer of the folded sheet or stack of folded sheets to another paper operation. The ejection device 146 can be mounted on the collecting device 104 to elevate a sheet 106 off the sheet-supporting edge 114 of the collecting device 104. The elevation and/or removal of the sheet can facilitate a further operation to transfer the stacked sheet of materials to a finishing operation in, for example, a booklet making operation.

In exemplary embodiments, the sheet collecting apparatus 100 can optionally comprise a fold blade support 148. An exemplary fold blade support 148 is shown in FIGS. 1A-1C and FIG. 2. The fold blade support 148 protrudes from the collecting device 104 in the second direction. The fold blade support 148 can be attached to the collecting device 104 or can be integral to the collecting device 104. The fold blade support 148 contacts the fold blade 102 when the collecting device 104 is in the first position (I). The fold blade support 148 can be in any suitable form that contacts the fold blade 102 and provides support for and/or transfers at least a portion of the forces exerted during a folding operation, e.g., by the cooperation of the housing 122 and the fold blade 102 to place folds in the sheets of material 106, from the folding blade 102 to the collecting device 104. For example, the fold blade support 148 may have a chamfered distal end that wedges under a second end of the fold blade 102 when the collecting device 104 is translated from the second position (II) to the first position (I). Any other suitable arrangement of the fold blade support 148 can be utilized that provides the fold blade 102 support during a folding operation.

The sheet collecting apparatus 100 can be an assembly within a larger sheet-wise booklet making system. An exemplary sheet-wise booklet making system can, for example, comprise the sheet collecting apparatus as described herein and a stapler 150. The stapler 150 in exemplary embodiments is mounted between the first position (I) and the second position (II) such that a sheet-supporting edge 114 of the collecting device 104 is positioned adjacent the stapler 150 as the collecting device 104 translates from the first position (I) to the second position (II). Staplers and stapler heads suitable for inclusion in the exemplary sheet-wise booklet making system are disclosed in commonly owned U.S. Pat. Nos. 6,554,267; 6,578,838; and 6,715,749.

FIG. 3 illustrates an exemplary method 300 to accumulate sheets on a collecting device on a sheet-wise basis. The exemplary method 300 comprises positioning a sheet-collecting portion of a collecting device below a fold blade 302, the sheet collecting portion having a peak with a longitudinal peak axis parallel to a fold axis of the fold blade, the peak axis and the fold axis each oriented in a first direction, transferring a sheet to the fold blade 304, folding a sheet on the fold blade to position a first portion of the sheet on a first side of the collecting device 306 and translating the collecting device in a translating direction parallel to the first direction such that the translating removes the folded sheet from the fold blade and transfers the folded sheet to the collecting device 307. As the collecting device translates in the translating direction, e.g., translates from the first position (I) to the second position (II), the operation of translating the collecting device removes the folded sheet from a free end of the fold blade. Transferring the folded sheet to the collecting device includes positioning a fold of the folded sheet to the peak of the collecting device. The method can be optionally repeated as necessary to transfer and position subsequent folded sheets on the collecting device.

In the exemplary method 300, the first portion of the sheet on the first side of the collecting device is positioned between the first side and a first sheet drive assembly. The exemplary method can comprise contacting the first sheet drive assembly against the first portion of the sheet prior to translating the collecting device. Contacting the first sheet drive assembly against the first portion of the sheet assists in pinning the sheet in position on the collecting device while the collecting device translates from the first position (I) to the second position (II) and removes the folded sheet from over the fold blade. Once the collecting device is in the second position (II), the first sheet drive assembly can be operated, e.g., power rotated, freely rotated, moved away from the side of the collecting device, or translated parallel to the side of the collecting device, such that the fold of the folded sheet comes to rest on the peak of the collecting device. Optionally, the method can include a similar operation for a second sheet drive assembly on a second side of the collecting device.

Although preferred embodiments have been described, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without department from the spirit and scope of the invention as defined in the appended claims. 

1. A sheet collecting apparatus, comprising: a fold blade having a fold axis in a first direction; a collecting device for supporting folded sheets of material in a stack arranged for stapling, the collecting device having a first side, a second side and a peak on a sheet-supporting edge, the peak having a peak axis in the first direction; and a translation device, the collecting device mounted to the translation device for translation in the first direction from a first position to a second position; wherein, in the first position, a sheet-collecting portion of the sheet-supporting edge subtends the fold blade, and wherein, in the second position, the sheet-collecting portion of the sheet-supporting edge is clear of the fold blade.
 2. The sheet collecting apparatus of claim 1, comprising a first sheet drive assembly including a first sheet contacting component, the first sheet drive assembly located on the first side of the collecting device and operable to move between a sheet receiving position and a sheet contacting position, wherein in a sheet-receiving position there is a gap between the first side of the collecting device and the first sheet contacting component.
 3. The sheet collecting apparatus of claim 2, wherein the first sheet contacting component is translatable in common with the collecting device.
 4. The sheet collecting apparatus of claim 2, wherein the first sheet contacting component is mounted to the collecting device.
 5. The sheet collecting apparatus of claim 2, comprising a second sheet drive assembly including a second sheet contacting component, the second sheet drive assembly located on the second side of the collecting device and operable to move between a sheet-receiving position and a sheet-contacting position, wherein in the sheet-receiving position there is a gap between the second side of the collecting device and the second sheet contacting component.
 6. The sheet collecting apparatus of claim 1, wherein the fold blade is cantilevered at a first end of the fold axis to a mounting surface.
 7. The sheet collecting apparatus of claim 6, wherein the translation device is mounted at a first end to the mounting surface.
 8. The sheet collecting apparatus of claim 1, wherein the translation device includes at least one rail with a longitudinal axis in the first direction and a drive motor operably attached to the collecting device to translate the collecting device from the first position to the second position.
 9. The sheet collecting apparatus of claim 1, comprising an ejection device mounted on the collecting device to elevate a sheet off the sheet-supporting edge.
 10. The sheet collecting apparatus of claim 1, comprising a fold blade support protruding from the collecting device in the second direction, the fold blade support contacting the fold blade when the collecting device is in the first position.
 11. A sheet-wise booklet making system comprising: the sheet collecting apparatus of claim 1; and a stapler, wherein the stapler is mounted between the first position and the second position and a sheet-supporting edge of the collecting device is positioned adjacent the stapler as the collecting device translates from the first position to the second position.
 12. A sheet collecting apparatus in a sheet-wise booklet making system, comprising: a fold blade having a fold axis in a first direction; and a collecting device for supporting folded sheets of material in a stack arranged for stapling, the collecting device having a first side, a second side and a peak on a sheet-supporting edge, the peak having a peak axis in the first direction, wherein the fold blade is cantilevered above a sheet-collecting portion of the sheet-supporting edge.
 13. The sheet collecting apparatus of claim 12, comprising: a translation device, the collecting device mounted to the translation device for translation in the first direction from a first position to a second position; and a first sheet drive assembly including a first sheet contacting component, the first sheet drive assembly located on the first side of the collecting device and operable to move between a sheet receiving position and a sheet contacting position, wherein, in the first position, the sheet-collecting portion of the sheet-supporting edge is below the cantilevered fold blade, as seen along the second direction, wherein, in the second position, the sheet-collecting portion of the sheet-supporting edge is clear of the fold blade as seen along the second direction, and wherein in a sheet-receiving position there is a gap between the first side of the collecting device and the first sheet contacting component.
 14. The sheet collecting apparatus of claim 13, wherein the first sheet contacting component is translatable in common with the collecting device.
 15. The sheet collecting apparatus of claim 13, wherein the first sheet contacting component is mounted to the collecting device.
 16. The sheet collecting apparatus of claim 13, comprising a second sheet drive assembly including a second sheet contacting component, the second sheet drive assembly located on the second side of the collecting device and operable to move between a sheet-receiving position and a sheet-contacting position, wherein in the sheet-receiving position there is a gap between the second side of the collecting device and the second sheet contacting component.
 17. A method to accumulate sheets on a collecting device on a sheet-wise basis, the method comprising: positioning a sheet-collecting portion of a collecting device below a fold blade, the sheet-collecting portion having a peak with a longitudinal peak axis parallel to a fold axis of the fold blade, the peak axis and the fold axis each oriented in a first direction; transferring a sheet to the fold blade; folding the sheet on the fold blade to position a first portion of the sheet on a first side of the collecting device; and translating the collecting device in a translating direction parallel to the first direction such that the translating removes the folded sheet from the fold blade and transfers the folded sheet to the collecting device.
 18. The method of claim 17, wherein translating the collecting device removes the folded sheet from a free end of the fold blade, and wherein transferring the folded sheet to the collecting device includes positioning a fold of the folded sheet to the peak of the collecting device.
 19. The method of claim 17, wherein the fold blade is cantilevered at a first end to a mounting surface and translating the collecting device removes the folded sheet from a free end of the fold blade, the free end opposite the first end along the fold axis.
 20. The method of claim 17, wherein the first portion of the sheet on the first side of the collecting device is positioned between the first side and a first sheet drive assembly and the method comprises contacting the first sheet drive assembly against the first portion of the sheet prior to translating the collecting device.
 21. The method of claim 20, wherein folding the sheet on the fold blade includes positioning a second portion of the sheet on a second side of the collecting device between the second side and a second sheet drive assembly and the method comprises contacting the second sheet drive assembly against the second portion of the sheet prior to translating the collecting device.
 22. The method of claim 17, wherein folding the sheet on the fold blade includes positioning a second portion of the sheet on a second side of the collecting device.
 23. The method of claim 17, comprising supporting the fold blade with a fold blade support projecting from the collecting device when the collecting device is in the first position.
 24. A method to assemble a booklet comprising: accumulating sheets on a collecting device on a sheet-wise basis according to claim 16; and binding the accumulated sheets to form the booklet. 